How many cables/ which cables to replace with 2g on CC DS IQ?

[Hkspwrsche]

On my 04 48volt CC DS IQ I am going to upgrade my cables. I don’t have a fancy diagram or anything since I bought them from my neighbor who has a non IQ 01 48 volt CC DS. My main concern is will I be missing some when I start replacing them due to some difference in carts. I don’t want to leave a small gauge cable in place that should have been changed.

Hoping to get a 2g cable layout for my DS IQ cart to do some verifying. May need to buy or make some to fill in any differences.

FYI- I don’t see an ultimate cable thread with advice, diagrams or specs. Maybe that would cover some of the other recent posts as well?

Thanks,
Harold

[_ogre]

cables are easy neg to pos for each battery :)

you need to pass thru the obc to charge correctly. #2 wire will not pass thru the obc hole, you need to use a brass stud, scottyb sells a obc cable stud kit http://www.cartsunlimited.net/ you can also make your own

here is a thread on obc stud kit https://www.buggiesgonewild.com/show...ht=toilet+bolt

[R&TBabich]

Originally Posted by Hkspwrsche

On my 04 48volt CC DS IQ I am going to upgrade my cables. .... Hoping to get a 2g cable layout for my DS IQ cart to do some verifying. May need to buy or make some to fill in any differences. ....

The main reason to upgrade the battery/controller/solenoid/motor circuit to 2 ga cables is if you are going to upgrade to a higher amp controller. I would start with the battery pack cables if the cables are original and 16 years old. You probably won't see any performance difference from the larger gauge cables, but they will hold up longer being near the batteries. The batteries can be installed in a couple of configurations. Our cart came wired like this, I don't know if it is factory, but I like the clean layout. There will 5 or 6 more cables to complete a 2 ga upgrade: B+ to solenoid, solenoid to controller, controller to motor, motor to controller, controller to B-. The controller to B- would be 2 pieces to go thru the OBC sensor as described in the previous post. I did an OBC delete to clean up the wiring.

[Hkspwrsche]

Originally Posted by _ogre

cables are easy neg to pos for each battery :)

you need to pass thru the obc to charge correctly. #2 wire will not pass thru the obc hole, you need to use a brass stud, scottyb sells a obc cable stud kit http://www.cartsunlimited.net/ you can also make your own

here is a thread on obc stud kit https://www.buggiesgonewild.com/show...ht=toilet+bolt

I recall seeing that. I heard you could lube the cable and push it through but, maybe that’s only recommend on 4g cable? Guess I need the bolt and at least one spare cable. He managed to push it though on his. I’ll take a look but, it won’t hurt to be safe.

[Hkspwrsche]

Originally Posted by R&TBabich

The main reason to upgrade the battery/controller/solenoid/motor circuit to 2 ga cables is if you are going to upgrade to a higher amp controller. I would start with the battery pack cables if the cables are original and 16 years old. You probably won't see any performance difference from the larger gauge cables, but they will hold up longer being near the batteries. The batteries can be installed in a couple of configurations. Our cart came wired like this, I don't know if it is factory, but I like the clean layout. There will 5 or 6 more cables to complete a 2 ga upgrade: B+ to solenoid, solenoid to controller, controller to motor, motor to controller, controller to B-. The controller to B- would be 2 pieces to go thru the OBC sensor as described in the previous post. I did an OBC delete to clean up the wiring.

Thanks! Sounds like not all 4 motor cable need to be upgraded or did I read that wrong?

[R&TBabich]

Originally Posted by Hkspwrsche

Thanks! Sounds like not all 4 motor cable need to be upgraded or did I read that wrong?

For sepex motors the field cables do not need to be upgraded, but some people have said move the 4 ga armature cables to replace the field cables which seems like a good idea.